Feature

Technologies for Helping Make
New Dreams Come True

1971
Ueda Works

50

November
2020

COLUMN
Cover image:

Ueda Works
1971

In the 1950s, demand for stepping motors was very limited in Japan. At
that time, our company's main products were DC servo motors and AC
servo motors. However, we were sure that stepping motor demand would
definitely grow in the near future, and had been advancing stepping motor
development.
Under these circumstances, we received a stepping motor sample orderfrom IBM Corporation of the United States, which was leading the worldin the field of computers at the time. We found it a great opportunity toprove our high technical expertise. We devoted all our efforts andsuccessfully developed a stepping motor that satisfied customer
expectations, leading to a mass production order.
At Ueda Works, young engineers established a mass production system,
and all our employees worked together to complete the project. This was
the moment when our next major product StepSyn was born, following
San Ace cooling fans. This achievement boosted our company's businesseven further.
In stepping motor windings, thin wires are used. Since this workrequired fine dexterity, a winding workplace consisting entirely of women
was added to Ueda Works. The stepping motor that was born in this way is
still playing an active role as one of our main products.

50
November 2020

SANYO DENKI TECHNICAL REPORT
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Technologies for Helping Make New Dreams Come True

Operating Officer Tatsuya Hirata

Feature: Technologies for Helping Make New Dreams Come True

1

3

■ Cooling Systems Division

Technologies for Helping Make New Dreams Come True
Splash Proof Fans
San Ace 60W, San Ace 80W, San Ace 92W

Honami Osawa ................ 3

Akira Nakayama and Others .............................. 9

40×40×28 mm High Static Pressure Fan
San Ace 40 9HVA Type Hikaru Urushimoto and Others ................................................................. 15■ Power Systems Division

Power Technologies
for Helping Make New Dreams Come True

Chiaki Seki ................................................ 20

Development of the SANUPS W75A Rectifier Unit for Wind Powerand Hydro Power Generation Systems Ryo Yoshizawa and Others ...................................... 24■ Servo Systems Division

Technologies for Helping Make New Dreams Come True

Hideaki Kodama and Others ... 28

Development of SANMOTION C Wireless Adapter 3A

Shigeki Sato and Others ............ 35

Technologies for Helping Make
New Dreams Come True
Tatsuya Hirata Operating Ofﬁcer

This fiscal year is the final year of our 8th Mid-term Management Plan. We
have been aiming to become a global company that is recognized as one of the
top brands in the world.
Although we have accomplished many of our initiatives, there are still somegoals that we will carry over to our 9th Mid-term Management Plan. In thisrespect, we still have many things we want to accomplish.
Looking back at our history, SANYO DENKI has overcome many major
challenges, such as the Great Depression of 1929, the Great Recession of 1945
following World War II, the oil crisis of 1974, and the financial crisis of 2008.
The current fiscal year has been dominated by an unprecedented change.
Needless to say, we are referring to COVID-19. COVID-19 has caused a lotof damage worldwide and has created unexpected environmental changes.
Turning this serious state of affairs into an opportunity is truly a daunting task.

It is against this backdrop that SANYO DENKI aims “to establish a
corporate culture capable of transforming environmental changes intobusiness opportunities.” To this end, each of our divisions is developing
businesses in new fields such as those that pertain to the 5th generation mobile
communications system (5G), business continuity planning (BCP), artificial
intelligence (AI), and electric vehicles (EV). In addition, the medical field ischanging significantly, and measures are being taken to combat COVID-19
infections. As part of this trend, many of our products are being used in PCR
testing equipment to detect people infected with COVID-19 and in testing
equipment used in the development of vaccines.
In today’s world of accelerated social change, we are developing productswith a view toward the needs of future market environments.
As mentioned previously, each of our divisions is developing new products
for the global market. For example, our Cooling Systems Division has
developed the San Ace C70 9TD type Centrifugal Fan, San Ace 40 9HVA

1SANYO DENKI Technical Report No.50 November 2020

type High Static Pressure Fan, and San Ace 60W, 80W, 92W 9WPA type highperformance Splash Proof Fans. Our Power Systems Division has developed
the SANUPS W75A rectifier unit for wind power and hydro power generation
systems and SANUPS N11B-Li equipped with lithium-ion batteries foroutdoor use that can be used with disaster-management ICT equipment. Our
Servo Systems Division has developed a SANMOTION R 3E Model AC servo
amplifier with built-in positioning functionality and the SANMOTION C 3A
wireless adapter for motion controllers.

The major theme of our 9th Mid-term Management Plan is to “break out of
our shells.” There are various types of shells, such as small ones, big ones, andvery difficult ones. Specifically, we must use the measures we have cultivatedover the years in combination with future initiatives to accomplish our goal of“leveraging our expertise to face the challenges of a changing global market.”This means that we are going to continue to advance the “new productdevelopment,” “borderless,” “real-time,” and “factory automation” themesof our 8th Mid-term Management Plan so that we can establish a corporate
pillar of “world-leading products.” Moving forward, we must strengthen ourmarketing strategies, sales strategies, and technical innovation, while cherishing
our relationships with customers to gain their trust. This will enable us tobuild new pillars (i.e., new customers) and fortify existing pillars (i.e., existingcustomers). To help achieve this, we will work hard to understand the issues
and challenges of our customers so that we can offer them products that meettheir needs. We are committed to contribute to society by identifying customer
needs, strengthening our product development accordingly, and ensuring that
our manufacturing and sales divisions work in unison. By doing this, we will beable to continue providing the world with “technologies for helping make new
dreams come true.”

SANYO DENKI Technical Report No.50 November 20202

Feature: Technologies for Helping Make New Dreams Come True

Technologies for Helping Make
New Dreams Come True
Honami Osawa

1. Introduction

shows the airflow vs. static pressure characteristics of thehighest-airflow models of our old and new fans of the same

The market has been demanding a variety of cooling fan

size. The order of product release was Fan A, B, C, D, thenfeatures, including those that provide high airflow, highE. It can be seen that newer products have better airflow vs.

static pressure, low noise, and low power consumption.

static pressure characteristics.

Market changes have further intensified these demands,

Figure 2 shows these models in a non-dimensional

and we have always developed new products aiming to meetmanner. The impeller and frame characteristics (such as

them. To continue to meet the market demand, which is

being a high airflow type or high static pressure type) can be

expected to continue to grow in the future, we will need todetermined by this process.

incorporate new technologies into our products.
Furthermore, there has also been demand for preventive

Fan A

maintenance of equipment by remotely controlling andthat enables efficient cooling and ventilation of equipmentusing a combination of various sensors. To meet theseneeds, we have developed San Ace Controller as theindustry’s first IoT-ready fan controller that can connect to

Fan B

Static pressure [Pa]monitoring the status of cooling fans, and for a system

Fan C
Fan D
Fan E

a network environment and remotely operate and monitor
fans using an external device. We developed this San AceController considering ventilation and pressure/humidity
control applications for new markets such as residential and

Airflow [m3/min]Fig. 1 Airflow vs. static pressure characteristics

housing equipment, industrial equipment, and agriculturalequipment. Nevertheless, we have received some requests to
In this article, we will describe new techniques forachieving higher cooling fan performance and new fancontroller technologies required in the future.

2. Enhance Cooling Fan Performance
2.1 Foreword
Before describing the performance improvements ofeach fan component, we would like to introduce the airflow

Fan A
Fan B

Pressure coefficient ψ

add new features to the controller.

Fan C
Fan D
Fan E

Flow coefficient φ

Fig. 2 Flow vs. pressure characteristic

vs. static pressure characteristics and flow vs. pressure
characteristics of our cooling fans that can be determinedfrom their structure and properties.

3

Flow vs. pressure characteristics show the aerodynamic
characteristics of fan impellers and frames. Put simply, theFigure 1 shows an example of the airflow vs. static

aerodynamic characteristics improve as the value increases (i.e.,pressure characteristics of our cooling fans. This graphas the curve moves toward the upper right corner of the graph).

SANYO DENKI Technical Report No.50 November 2020

Technologies for Helping Make New Dreams Come True

By comparing these two graphs, it can be seen that thelatest model has the highest airflow vs. static pressure
the aerodynamic characteristics of its impeller and frame.
This means that it is the motor and circuit combination of
the latest model that achieves the highest airflow vs. staticpressure characteristics.

Static Pressure

characteristics by far, but this is not the case with respect toTherefore, to improve cooling fan performance, it isimportant to appropriately improve the following:(1) Aerodynamic performance(2) Motor performance(3) Drive circuit performancePower

Fig. 3 Example of simulation-based design
optimization
In this example, electric power is on the horizontal axis

It should also be noted that the fans in Figures 1 and 2

and static pressure on the vertical axis. Impeller and frame

are all the same size. It can be said, then, that the graph inefficiency improves as the curve moves toward the upper left

Figure 2 is a comparison of aerodynamic characteristics at

corner of the graph. The triangular plots (△) were obtained

the same rotational speed. Accordingly, technologies thatthrough conventional trial and error approach, while theachieve high airflow vs. high static pressure characteristics

circular plots (○) were obtained using recent simulation

are highly dependent on improvements in the rotational

technology. This shows that the new approach enables the

speed of the motor.

design of lower-power cooling fans with the same static

We will now describe the techniques for enhancing
performance by improving fan components.

pressure values.
With simulation-based design optimization, we can use
parameters that inherit the expertise incorporated into our

2.2 Improve aerodynamic performanceprevious products, and then add new parameters to realize

The design of impellers and frames conventionallycompletely new types of impeller and frame designs. Withrequired repeated trial and error. This approach was very

this approach, we aim to achieve the industry’s highest

time-consuming and tedious.

cooling fan performance.

In recent years, improvements in computer speed
and simulation technologies have made it possible to

2.3 Enhance motor performance

automate the design process. “Simulation-based design

As mentioned in Section 2.1, newer models do not

optimization” is an approach in which a computer designs

necessarily have better aerodynamic performance. Impeller

the optimal shape through trial and error based on required

and frame combinations that achieve high aerodynamic

performance conditions. This type of approach is becoming

performance require a motor with high torque. To achieve

more and more realistic, and we have also been using it inthis, the diameter of the motor will usually need to be

our company.

increased. A larger motor diameter can result in a smaller

Figure 3 provides an example of simulation-based design
optimization.

ventilation area, which in turn can create the differences inaerodynamic performance shown in Figure 2.
However, if the diameter of the motor can be reduced
while maintaining its torque and reliability, this would
enable the combination with an impeller and a frame thatrealizes high aerodynamic characteristics.
I n t he fol low i n g s e c t io n s , we w i l l d e s c r ib e t heminiaturization and efficiency enhancement of motors.
Higher motor efficiency means less loss. Motors are
susceptible to the following types of loss:(1) Copper loss
(2) Iron loss(3) Mechanical loss

SANYO DENKI Technical Report No.50 November 2020

4

A large proportion of the loss is occupied by (1) and (2).

to the increased drive frequency of today’s high-speed

In the next section, we will introduce some techniques formotors, eddy current loss has also been increasing. A

reducing each type of loss.

solution to this problem is to laminate thinner steel
sheets in a manner that reduces eddy current loss.

2.3.1 Reduction of copper loss
The following techniques are used to reduce copper loss:(3) Magnetic circuit design for motors
To d evel o p a m o t o r t h at m e et s t h e r e qu i r e d(1) Use of magnets with strong magnetic force
The use of magnets with strong magnetic force isnecessary to generate a sufficient amount of torquespecifications by incorporating the above-mentioned
copper and iron loss reduction measures, it is necessary
to optimally use the space inside the motor.

using low currents. In this regard, the use of rare-earth

Electromag netic f ield a na lysis is cu r rently

magnets, such as neodymium, alnico, and samarium

indispensable for designing motors. By using analysis

cobalt, instead of current mainstream ferrite magnets,

techniques to optimize the structure and magnetic

can facilitate the reduction of copper loss.

circuit, we have been designing highly efficient andreliable motors.

(2) Improvement in the winding fill factor
Improvement in the winding fill factor is necessary to

2.4 Improve circuit performance

reduce the Joule loss caused by the current and winding

Improvements in cooling fan performance have been

resistance of the motor. This can be accomplished byaccompanied by increased power consumption, requiring

increasing the conductor’s cross-sectional area andthe use of devices that drive high currents. In general,

improving the winding technique.

these types of devices are large in size and generate a lot

Specifically, flat wire can be used to increase theof heat. Also, designs that prioritize the optimization of

conductor’s cross-sectional area while techniques such as

aerodynamics limit the space (diameter) available foraligned winding can be used to realize a higher fill factor;

the PCB and decrease the area available for mounting

both help reduce copper loss.

electronic components.

2.3.2 Reduction of iron loss

when designing circuits:

For these reasons, the following two measures are needed
Iron loss can be reduced by improving the magnetic
material and the shape and structure of the stator (iron(1) Compact component mountingcore).

(2) Heat dissipation measures for electronic components andWe will now mainly describe some technical measures for

the PCBstators.
In the following sections, we will describe some solutions(1) Use of electromagnetic steel sheets with low iron loss andto these challenges.

high magnetic flux density
In recent years, silicon steel sheets have been used forstators, but the following materials have been attracting
attention:

2.4.1 Compact component mounting
A s ment ione d prev iou sly, de sig n s t hat opt i m i z e
aerodynamics limit the space available for the PCB
and decrease the area available for mounting electronic•

Fe-based amorphous

components. The following two approaches can be taken to•

Nanocrystalline soft magnetic materials

solve these challenges:•

Fe magnetic powder cores(1) Reduce the number of components

These materials are all characterized by their low ironloss and low eddy current loss, making them worthy for(2) Use BGA (ball grid array) and LGA (land grid array)package components

future consideration as stator materials.
Modules such as intelligent power modules (IPMs) can

5(2) Thickness optimization for electromagnetic steel sheets

be used to reduce the number of components. Since IPMs

C u r rently, electromag netic steel sheets w ith a

integrate power devices and the drive circuit into a single

thickness of 0.35 mm are widely used. However, due

module, they can reduce the number of components,

SANYO DENKI Technical Report No.50 November 2020

Technologies for Helping Make New Dreams Come Truecontributing to space-saving mounting and smaller PCB

approaches, need to make use of conduction-based heat

designs.

dissipation.

Figure 4 shows an example of a conventional circuit andIn recent years, conduction-based heat dissipation has
been used in compact sealed devices, such as smartphones,

Figure 5 shows a circuit using an IPM.

digital cameras, and engine control units (ECUs), andwe believe that this method should be considered when+

designing cooling fan circuits.

Step-down
circuit

The following five methods are used to improve heat

Gate
driverIC

CPUordriver IC

Currentlimiting
circuitU

dissipation in sealed devices:GatedriverIC

V(1) Reduction of thermal resistance between components

GatedriverIC

W

and the PCB(2) Improvement of the PCB’s thermal conductivity(3) Reduction of contact thermal 図版の文字
resistance

GND(4) Use of a heat spreader

Fig. 4 Conventional circuit example

123

英語版用

Condens(5) Improvement of the housing’s
thermal conductivity
英語版用

performance

Times Ten

Figure 6 provides a reference example.

+
Step-down
circuit

図版の文字
U

CPU
or
driver IC

IPM(1) Reduction of thermal resistance
between components and the PCB

123(3) Reduction of contact
thermal resistance

Increased contact area ofcopper foilHigh thermal conductivity
and flexibility

V

TIM
Components
In contact

Thermal via(6) Securing surface area

英語版用

Condens

Heat sink shape optimized

英語版用

Housing

Times Ten

Internal heat dissipation components

W
PCB

In contact

SpreaderGND

Fig 5 Example of circuit with IPM(4) Use of a heat spreader

Increased thermal
conductivity inthe
surface directions(5) Improvement of the housing’s
thermal conductivity

High thermal conductivity,
high thermal emissivity

In this example, the components inside the dotted line
in Figure 4 are integrated into an IPM. This contributes toreducing the number of components and the mounting area.

(2) Improvement of the
PCB’s thermal
conductivity

Material with highthermal conductivity
Use of copper foil
Use of thermal via

Fig. 6 Improving heat dissipation in sealed devices

The use of BGA and LGA packages ensures that the leadsof electronic components do not protrude outside of theirpackage. This helps reduce the mounting area.
These techniques have already been applied to some of

We bel ieve that these methods ca n be used w ith
cooling fans to dissipate the heat generated by electronic
components, and will help further improve their reliability.

our cooling fans and are expected to be used more in the
future.

2.4.2 Heat dissipation measuresfor electronic components and the PCB

3. New Technologies
for Fan Controllers
3.1 Foreword

The motor and circuitry of cooling fans are generally not

T h e r e h a s b e e n m a r ket d e m a n d fo r p r eve nt i ve

sealed. As a result, we have taken measures to promote heat

maintenance of equipment by remotely controlling anddissipation due to convection and radiation caused by themonitoring the status of cooling fans, and also for a system

flow of air from the rotating impeller.

that enables efficient cooling and ventilation of equipment

As power consumption and mounting density increasein circuits, we expect that cooling through conventional
approaches alone will become difficult. The circuit designsof cooling fans in the future will, in addition to conventional

using a combination of various sensors. To meet these needs,
we have developed San Ace Controller.
After releasing the controller, we started receiving thefollowing requests from the market:

SANYO DENKI Technical Report No.50 November 20206

(1) Enhancement of sensor-based monitoring and control

PC(2) Open network support
We will now discuss these feature requests.

Ethernet

3.2 Enhancement of sensor-based
monitoring and control
The current San Ace Controller supports the following
dedicated sensors:•

Temperature sensor•

Humidity sensor•

Barometer•

Accelerometer
In addition to these, the market is requesting support for

the following sensors:

Fig. 7 Configuration example for the current model•

Dust sensor•

Odor sensor•

Presence sensor

Master controller
To meet customer requirements, we plan to develop these
dedicated sensors to enhance the functionality of San Ace

Open network

Controller.

3.3 Open network support
The wired communication that the current San Ace
C ontrol ler suppor ts is Ether net. However, there is

SensorSensor Device Device

increasing market demand for communication with slaves(sensors and external devices) that use open networks, suchas EtherCAT and OPC UA (open platform communications

Slaves supporting open network

unified architecture).
Figure 7 shows a configuration example for the current
model, and Figure 8 shows a configuration example for amodel with open network support.

Fig. 8 Configuration example for an open network
supported model

7

SANYO DENKI Technical Report No.50 November 2020

Technologies for Helping Make New Dreams Come True

We currently do not offer a fan controller that supports

Authoropen networks, so we need to develop one. Such a controller
can control commercially available slaves. We are willing to

Honami Osawa

develop one in the future because such a product can expand

Cooling Systems Div., Design Dept.
Works on the development and design of cooling fans.

the scope of application for customers.

4. Conclusion
In this article, we described techniques for achieving
higher airflow and static pressure for cooling fans, and also
the new fan controller features and specifications.
T he market is demanding not only higher airf low
and static pressure, but also decreased noise, power
consumption, and cost. We are working to meet thesedemands by employing new technologies and approaches.
Our current fan controller is the first in the industry toprovide IoT features, and more requests will be expected in
the future. We plan to meet these requests through featureenhancement and new fan controller development.
The Design Department in our Cooling Systems Division
will continue to constantly develop new products. We
are committed to always developing the industry’s bestproducts. Furthermore, we plan to continue developing andproviding products that help our customers realize their
dreams by identifying market changes and demands and byoffering the best products and timely customizations.
References(1) Naoki Kunimine: “Heat Dissipation Measures for High-Density
Electronics in the 5G Era”
Nikkei xTECH Learning seminar (July 2020)(2) Osamu Ichinokura: “Recent Motor Technology”
http://www.aki.che.tohoku.ac.jp/170116web/O.Ichinokura_web0118.pdf (2020.8.24)(3) Naoki Murakami and 7 others: Development of San AceController, an IoT Product for Remote Fan Control and Monitoring
SANYO DENKI Technical Report, No.48, pp. 8-13 (2019.11)(4) Michinori Watanabe: Technical Developments in 2019 at Cooling
Systems Division
SANYO DENKI Technical Report, No.49, pp. 3-5 (2020.5)

SANYO DENKI Technical Report No.50 November 20208

New Product Introduction

Splash Proof Fans San Ace 60W,
San Ace 80W, San Ace 92W
Akira Nakayama

Jane Oliva

Rogen Molino

Grace Rico

Jovelyn Villar

Tetsuya Yamazaki

Shigekazu Mitomo

Takashi Kaise

Yukihiro Nagatsuka

Yoshihisa Yamazaki

1. Introduction

The new models’ structural features are as follows.

Due to their enhanced performance and smaller sizes,(1) Figure 4 shows the coating on the live parts. Live parts

today’s outdoor base stations, photovoltaic inverters, and(windings and circuits) are coated with a protective

digital signage are generating more heat. As a result, thematerial with excellent waterproof performance.

splash proof fans used in these applications must provide
greater cooling performance than ever before.
To meet this demand, we developed and released threehigh-performance Splash Proof Fans that provide greater
cooling performance (high airflow and high static pressure)than our current models. These are the San Ace 60W, San
Ace 8 0W, and San Ace 92W 9WPA types (hereinafter,“new models”). This article introduces the features andperformance of the new models.

2. Product Features
Figures 1 through 3 show the appearance of the new models.
The new models maintain compatibility with the current

Fig. 4 Coating of electrical component

models in sizes and mounting hole positions, while achieving
higher airflow and static pressure.

Fig. 1 60 × 60 × 25 mm
San Ace 60W 9WPA type9

Fig. 2 80 × 80 × 25 mm
San Ace 80W 9WPA type

SANYO DENKI Technical Report No.50 November 2020

Fig. 3 92 × 92 × 25 mm
San Ace 92W 9WPA type

Splash Proof Fans San Ace 60W, San Ace 80W, San Ace 92W

3. Product Outline(2) Figure 5 provides a comparison of the frame shapes of
the new models and the 9WL type fans. The frame is

3.1 Dimensions

made of plastic (rasin), but maintains compatibility inshape with our current 9WL type fans with aluminum

Figures 6 through 8 show the dimensions of the newframes.

models.
T he fans’ external dimensions and mounting hole
Current models
Aluminum (9WL type)

dimensions are unchanged and compatible with our current

New models
Plastic (9WPA type)models.

3.2 Specifications

60 × 60 mm

Tables 1 shows the general specifications for the newmodels.
Rated voltages of 12 V and 24 V are available to support
operation in a wide range of applications.
The models are equipped with a PWM control function

80 × 80 mm

to regulate fan speed according to equipment internal
temperatures, to facilitate the reduction of equipment power
consumption.
The new models have an expected life of 40,000 hours at
92 × 92 mm

60˚C (survival rate of 90%, run continuously at rated voltage
and normal humidity in free air).
The airflow vs. static pressure characteristics in figures
9 through 11 show the respective rated voltages and upper

Fig. 5 Frame shape comparison
with the current 9WL type fansand lower limits of their operating voltage ranges.

4±0.5

60±0.550±0.3

4±0.5

+50
0

50±0.3300

25±0.5(10)60±0.54-ø4.5±0.3

Rotating direction

Airflow direction

Fig. 6 Dimensions of San Ace 60W (Unit: mm)

80±0.5(4)71.5±0.371.5±0.3

(4)

+50
300 0

80±0.525.2±0.5

4-ø4.5±0.3(10)Rotating direction
Airflow direction

Fig. 7 Dimensions of San Ace 80W (Unit: mm)

SANYO DENKI Technical Report No.50 November 202010

25.2±0.5

92±0.5(4)(4)

82.5±0.382.5±0.3

+50
300 0

92±0.54-ø4.5±0.3(10)Rotating direction

Airflow direction

Fig. 8 Dimensions of San Ace 92W (Unit: mm)Table 1 General specifications for the new models
Model no.

Rated
voltage[V]

Operatingvoltagerange[V]

9WPA0612P4G001

1210.8 to 13.2

9WPA0624P4G001

24

21.6 to 26.4

9WPA0812P4G001

1210.8 to 13.2

9WPA0824P4G001

24

21.6 to 26.4

9WPA0912P4G001

1210.8 to 13.2

9WPA0924P4G001

24

21.6 to 26.4

PWM
Rated Rated
duty
current input
cycle*
[A]
[W]
[%]
100
0.93 11.16
0.09
1.08
20
100
0.46 11.04
0.05
1.2
20
100
0.71
8.52
0.07
0.84
20
100
0.36
8.64
0.05
1.2
20
100
0.5
6
0.04
0.5
20
100
0.25
6
0.03
0.7
20

Rated
Max. airflow
speed-1[min ] [m 3/min] [CFM]
12000
1.52
53.7
3500
0.41
14.5
12000
1.52
53.7
3500
0.41
14.5
8250
2.32
81.9
2400
0.67
23.6
8250
2.32
81.9
2400
0.67
23.6
5700
2.45
86.5
1200
0.52
18.4
5700
2.45
86.5
1200
0.52
18.4

Sound Operating
Expectedpressure temperatureservice life
level
range
[h]
[Pa] [inchH 2O] [dB(A)]
[˚C]
357
1.44
56
31
0.13
22
357
1.44
56
31
0.13
22
210
0.84
54
40000
18.2 0.073
21
at 60˚C-20 to +70(70000 at
210
0.84
54
40˚C)
18.2 0.073
21
126
0.51
47
6
0.02
11
126
0.51
47
6
0.02
11
Max. staticpressure* Input PWM frequency: 25 kHz; speed is 0 min -1 at 0% PWM duty cycle.
Note: The expected life at an ambient temperature of 40˚C is for reference purpose only.
[inchH2O] [Pa]500
2.0[inchH2O] [Pa]240

12/24 VDC

400

220

0.8

200

0.7

100% PWM duty cycle
300

Static pressure

Static pressure

1.5

0.9

1.0
200

0.6

0.5
100

20% PWM duty cycle

0
0

0.25

0.5

10

20

0.75

1.0

30
Airflow

1.25
40

1.5
50

1.75 [m3/min]
60

[CFM]

Fig. 9 Airflow vs. static pressure characteristics
of San Ace 60W

11

SANYO DENKI Technical Report No.50 November 2020

140

0.4

100

0.1
0

160

120

0.2

0

100% PWM duty cycle

180

0.5

0.3

12/24 VDC

80
60
20% PWM duty cycle

40
20
0

0.5
0

20

1.0

1.5
40
Airflow

2.060

2.5 [m3/min]
80

[CFM]

Fig. 10 Airflow vs. static pressure characteristics
of San Ace 80W

Splash Proof Fans San Ace 60W, San Ace 80W, San Ace 92W[inchH2O] [Pa]
160

250

12/24 VDC

0.6

1.19 2.6
times times

140

0.4

200

100% PWM duty cycle

120
100

Static pressure [Pa]Static pressure

0.5

80

0.3

60
0.2

New model
9WPA0812P4G001

150

Current model
9WL0812P4J001

100

40
0.1

20% PWM duty cycle

20

0

0

0.5
0

1.0

20

1.5
40

50

2.0

60
Airflow

2.580

3.0 [m /min]
100

0

[CFM]

Fig. 11 Airflow vs. static pressure characteristics
of San Ace 92W

1.55 times

Current model
9WP0812G401

3

0

0.5

1.12 times

1

1.5
2
Airflow [m3/min]

2.5

3

Fig. 13 Comparison of the airflow
vs. static pressure characteristics
for the new and current San Ace 80W models

4. Comparison with Current Models

150

4.1 Comparison of airflow
vs. static pressure characteristics

1.2
1.9
times times

Figures 12 through 14 compare the airflow vs. staticpressure characteristics of the new and current models.
Compared to the current models, the new models have400
1.19 2.3
times times

100

New model
9WPA0912P4G001

Static pressure [Pa]greater maximum airflow and maximum static pressure.

Current model
9WL0912P4J001
50

Static pressure [Pa]300
Current model
9WP0924G401
New model
9WPA0612P4G001

1.11 times
0200
Current model
9WL0612P4S001

0.5

0.5

1

1.5
2
Airflow [m3/min]

2.5

3

1.4 times

Current model
9WP0624J401
00Fig. 14 Comparison of the airflow
vs. static pressure characteristics
for the new and current San Ace 92W models

100

01.39 times

1.08 times
1
Airflow [m3/min]

1.5

2

Fig. 12 Comparison of the airflow
vs. static pressure characteristics
for the new and current San Ace 60W models

SANYO DENKI Technical Report No.50 November 2020

12

5. Key Points of Development

120

6
Current model
9WP0812G401

The new models offer higher airflow and static pressure
100

than the current models while featuring good waterproof

5

performance.

4.56 Wmethod to achieve lower power consumption.
The key points of development are explained below.

5.1 Structural design

Static pressure [Pa]

achieve higher performance than the current models.
Furthermore, they have a high-efficiency motor and drive

24% reduction

80

3.5 W
New model(Max. airflow aligned)
9WPA0812P4G001

60

3

40

2

To achieve an IP68-rated water protection,* we ensured

Current model
9WP0812G401

that all live parts are coated with plastic that is highly
waterproof and resistant to temperature changes. Reliability

4Power consumption [W]We designed the new models to have higher speeds to20

1

and productivity have been improved by optimizing thecoating shape.
The frame is made of plastic to help achieve the desired
performance of the product. It is designed to support thehigher speeds of the fans.
* Protection rating The degree of protection (IP code) is definedby IEC (International Electrotechnical Commission) 60529 as“Degrees of Protection Provided by Enclosures (IP Code)” (IEC:60529:2001)

5.2 Motor and circuit
The new models have a new circuit design to realize higher
performance. By adopting a high-efficiency motor and drive

0

0.5

1
Airflow [m3/min]

1.5

2

0

Fig. 15 Power consumption comparison
with the current model

6. Conclusion
This article introduced the features and performance of
our San Ace 60W, San Ace 80W, and San Ace 92W 9WPA
type high-performance Splash Proof Fans.

system, the new models are able to suppress the amount ofCompared with current models, the three new models

motor heat generation. This made it possible to attain higher

provide higher airflow and static pressure. We expect

speeds.

that the new models will make a significant contribution

I n addition, the new models ach ieve lower power

to sophisticated applications that require higher cooling

consumption than that of the current 9WP type fans at theperformance such as base stations, photovoltaic inverters,same airflow. Figure 15 compares the power consumption

and digital signage.

and the airflow vs. static pressure characteristics between

We will continue developing products in response to

the new San Ace 80W model and a current model at thevarious market needs. In particular, we plan to continue

same maximum airflow.

offering products in a timely manner which contribute to the

The new model has higher static pressure and lower
power consumption than the current model in all operating
regions.
Moreover, we were able to reduce the nu mber ofcomponents by using new components.

13

0

SANYO DENKI Technical Report No.50 November 2020

creation of new value for our customers to help make their
dreams come true.

Splash Proof Fans San Ace 60W, San Ace 80W, San Ace 92W

AuthorAkira Nakayama
SANYO DENKI PHILIPPINES, INC., Design Dept.
Works on the development and design of cooling fans.

Jane Oliva
SANYO DENKI PHILIPPINES, INC., Design Dept.
Works on the development and design of cooling fans.

Rogen Molino
SANYO DENKI PHILIPPINES, INC., Design Dept.
Works on the development and design of cooling fans.

Grace Rico
SANYO DENKI PHILIPPINES, INC., Design Dept.
Works on the development and design of cooling fans.

Jovelyn Villar
SANYO DENKI PHILIPPINES, INC., Design Dept.
Works on the development and design of cooling fans.

Tetsuya Yamazaki
SANYO DENKI PHILIPPINES, INC., Design Dept.
Works on the development and design of cooling fans.

Shigekazu Mitomo
Cooling Systems Div., Design Dept.
Works on the development and design of cooling fans.

Takashi Kaise
Cooling Systems Div., Design Dept.
Works on the development and design of cooling fans.

Yukihiro Nagatsuka
Cooling Systems Div., Design Dept.
Works on the development and design of cooling fans.

Yoshihisa Yamazaki
Cooling Systems Div., Design Dept.
Works on the development and design of cooling fans.

SANYO DENKI Technical Report No.50 November 202014

New Product Introduction

40×40×28 mm
High Static Pressure Fan
San Ace 40 9HVA Type
Hikaru Urushimoto

Katsumichi Ishihara

Atsushi Yanagisawa

Shuji Miyazawa

Toshiyuki Nakamura

Hiromitsu Kuribayashi

1. Introduction

High performance has been achieved while maintaining
the size of the current model.

In the 1U server and ICT equipment market, there isincreasing demand for high-performance compact cooling fanscapable of supporting equipment with enhanced functionalityand denser component mounting conditions. Furthermore,in recent years, many customers have emphasized the needto reduce power consumption. To do this, it is important toachieve high static pressure and energy savings.
To meet these requirements, we have developed andreleased the San Ace 40 9HVA type High Static Pressure Fan(hereinafter, “new model”) which features a newly designed
impeller, frame, motor, and circuit.
This article will introduce some of the features andFig. 1 40 × 40 × 28 mm San Ace 40 9HVA type

performance of the new model.

2. Product Features

3. Product Outline
3.1 Dimensions

Figure 1 shows the appearance of the new model.
The features of the new model are:Figure 2 shows the dimensions of the new model. The
fan’s external dimensions and mounting hole dimensions areunchanged and compatible with our current model.

(1) High static pressure(2) Low power consumption

4-ø3.5±0.3(4)28±0.540±0.3(4)32±0.3(10)

Airflow direction

Rotating direction

Fig. 2 Dimensions of the new model (Unit: mm)

15

SANYO DENKI Technical Report No.50 November 2020

40±0.332±0.3+30
320 0

40×40×28 mm High Static Pressure Fan San Ace 40 9HVA Type

3.2 Specifications
3.2.1 General specifications
Table 1 shows the general specifications for the new model.
The rated voltage is 12 VDC and the rated speed is 38,000
min-1 (J speed), making it suitable for the 1U server market.

Table 1 General specifications for the new model
Model no.

OperatingMax. airflow
Rated
PWM duty Rated Rated Rated
voltagevoltagecycle* current input speed
range
[V]
[%]
[A]
[W] [min-1] [m3/min] [CFM][V]

9HVA0412P3J001

10.2
to
13.8

12

Max. staticpressure[Pa]

OperatingExpected
SPL temperatureservice life[dB(A)]
range[h][inchH2O]
[˚C]

100

2.60

31

38000

1.05

37.1

2300

9.24

71

20

0.12

1.4

8000

0.22

7.8

101

0.41

34

-20 to +70

30000
at 60˚C(53000at 40˚C)* Input PWM frequency: 25 kHz; speed is 0 min-1 at 0% PWM duty cycle.
Note: The expected life at an ambient temperature of 40˚C is for reference purpose only.

3.2.2 Airflow vs. static pressure
characteristics

3.3 Expected life
The new model has an expected life of 30,000 hours at

F i g u r e 3 s h ow s t h e a i r f l ow v s . s t a t i c p r e s s u r e
c h a r a c t e r i s t i c s fo r t h e n e w m o d e l . I t s h o w s t h e

60°C (survival rate of 90%, run continuously at rated voltage
and normal humidity in free air).

characteristics at 100% and 20% PWM duty cycles at a rated

4. Key Points of Development

voltage of 12 V.

3.2.3 PWM control function

The new model achieves a significant improvement in

The new model has a PWM control function that enables

static pressure compared to our current 40 × 40 mm fans.
To achieve the target static pressure performance, it was

external control of fan speed.
S e e F ig u re 3 for t he a i r f low v s . st at ic pre s su renecessary to increase the speed of the motor, while also
optimizing the shape of the impeller and frame.

characteristics at different PWM duty cycles.

The impeller, frame, motor, and circuit were all newly[inchH2O] [Pa]2500
10designed to achieve these goals.

12 VDCIn the following sections, we will describe the main featuresof the new model as well as the differences between it and the

8

2000

6

1500

San Ace 40 9HV type (hereinafter, “current model”).

Static pressure

100% PWM duty cycle

4

4.1 Impeller and frame design
To ach ieve a sig n i f ic a nt ly h ig her st at ic pres su reperformance than the current model, the fan speed of the1000

new model had to be increased to 38,000 min-1, while also
optimizing the shape of the impeller and frame. Since this2

20% PWM duty cycle

500

is the fastest speed among all of our fans, we designed theimpeller to withstand it.

0

0

0.2
0

0.4
10

0.6
20

0.8
30

1.2 [m3/min]

1.0
40

[CFM]

Airflow

Fig. 3 Airflow vs. static pressure characteristicsof the new model

In addition, the current model used aluminum as theframe material, but the new model uses resin to reduceweight. Resin has lower heat dissipation performance thanaluminum, and this makes cooling down the motor moredifficult. However, we improved its cooling performance byadjusting the number and size of the impeller’s vent holes.
Figure 4 shows an impeller shape comparison for thecurrent model and new model.

SANYO DENKI Technical Report No.50 November 202016

Vent holes(5 places)

Vent holes(8 places)

impeller’s ventilation holes, as mentioned above. As a result,
we achieved a high-speed fan circuit design that uses thesame PCB size as the current model.

5. Comparison with Current Model
5.1 Comparison of airflow
vs. static pressure characteristics
Figu re 6 compares the ai r f low vs. static pressu reCurrent model

New model

Fig. 4 Impeller shape comparison between current
and new models

characteristics of the new model and the current model.
Airflow and static pressure have been improved 1.26
times and 2.1 times that of the current model, respectively.
According to the estimated system impedance curves in the
figure, the new model’s operating airflow is 28% higher than

4.2 Motor and circuit design

the current model when used in a device with low system

Figure 5 shows the motors of the current model and new

impedance. Furthermore, its operating airflow is 33%

model. To achieve a higher fan speed, it was necessary tohigher than the current model when used in a device with

develop a circuit that would provide current to the motor

high system impedance.

through high-frequency switching, while also reducing
motor vibration. To accomplish these, we designed a new

2600

circuit and motor; the new circuit suppresses peak current

Voltage: 12 V
PWM duty cycle: 100%

2400

values even at high switching speeds and the new 3-phasemotor provides low cogging torque and vibration.

Current model 9HV0412P3K001
New model 9HVA0412P3J001

2200
2000
33% higher operating airflow
1800

Static pressure [Pa]1600

Current model(single-phase drive)

New model(3-phase drive)

Fig. 5 Motors of the current and new models
The higher speed has increased power consumption to
31 W. As a result, the new model consumes the most power

1400
1200
1000
800
600
400

Estimated system
impedance

among all of our 40 × 40 mm fans. This 1.7 times higher
power consumption than the current model raised an issueof heat generated by electronic components. If a larger
fan size could be used, the size of the PCB could also beenlarged. This would enable the use of large components
with high current-carrying capacities or the use of multiple
electronic components to facilitate heat dissipation.
However, 40 × 40 mm fans do not support larger PCBs
because the larger board size would reduce the ventilation
area and degrade aerodynamic performance. It was against
this backdrop that we decided to optimize the component
layout so as to maximize the internal cooling effect of the17

SANYO DENKI Technical Report No.50 November 2020

28% higher operating airflow

2.1 times

200
0

0

0.2

0.4

0.6
Airflow [m3/min]

0.8

1

1.2

1.26 times

Fig. 6 Airflow vs. static pressure characteristicsof the new and current models

40×40×28 mm High Static Pressure Fan San Ace 40 9HVA Type

5.2 Comparison of power consumption
at an equivalent performance level
as the current model

5.3 Comparison
with a 40 × 40 × 56 mm productThe cooling performance of the new model even exceeds

Figure 7 provides a comparison of power consumption
for the current and new models at equivalent coolingthat of a 40 × 40 × 56 mm Counter Rotating Fan, whose
thickness is twice that of the new model.

performance. When the fan speed of the new model is

Figure 8 provides a comparison of the airf low vs.

reduced with PWM control to obtain the same coolingstatic pressure characteristics with a 40 × 40 × 56 mm

p er for m a nc e a s t h at of t he c u r rent mo del , p ower

9CRV0412P5J201 Counter Rotating Fan.

consumption is lower across all operating ranges. In

The maximum static pressure of the new model is 2.2

particular, it is 20% lower near the maximum airflow andtimes higher than that of the even thicker Counter Rotating

10% lower in the high static pressure range. This reduces

Fan, and its cooling performance is greater across all

running costs for the new model.

operating ranges. As a result, the new model will be effectivein space saving.

1600

20
2600
16
10% reduction

20% reduction
121200
Voltage: 12 V
Current model 9HV0412P3K001

8

New model 9HVA0412P3J001(80% PWM duty cycle)

2200
2000
1800
1600

4

800

0

600

400

Static pressure [Pa]Static pressure [Pa]1000

Voltage: 12 V
PWM duty cycle: 100%

2400
Power consumption [W]1400

New model
9HVA0412P3J001

1400
2.2 times

1200
1000

Estimated system
impedance

800

200
600
0

0

0.2

0.4
0.6
Airflow [m3/min]

0.8

1Fig. 7 Airflow vs. static pressure characteristics(Compared with the current model)

400
Current model
9CRV0412P5J201

200
0

0

0.2

0.4

0.6
0.8
Airflow [m3/min]

1

1.2

Fig. 8 Airflow vs. static pressure characteristics(Compared with a 40 × 40 × 56 mm
Counter Rotating Fan)

SANYO DENKI Technical Report No.50 November 202018

40×40×28 mm High Static Pressure Fan San Ace 40 9HVA Type6. Conclusion
In this article, we introduced some of the features andperformance of the 40 × 40 × 28 mm San Ace 40 9HVA typeHigh Static Pressure Fan.

Author

Hikaru Urushimoto
Cooling Systems Div., Design Dept.
Works on the development and design of cooling fans.

Compared to our current model, the new model offers
significantly higher static pressure. Furthermore, when

Katsumichi Ishihara

cooling performance is equivalent to that of the current

Cooling Systems Div., Design Dept.
Works on the development and design of cooling fans.

model, the new model greatly reduces power consumption.
We expect that the high static pressure and low power
consumption features of the new model will make a

Atsushi Yanagisawa

significant contribution to the market by facilitating energy

Cooling Systems Div., Design Dept.
Works on the development and design of cooling fans.

savings and cooling in high-density devices.
We plan to continue developing cooling fans that makeuse of the most advanced technologies so that we can

Shuji Miyazawa

quickly adapt to customer needs.

Cooling Systems Div., Design Dept.
Works on the development and design of cooling fans.

Toshiyuki Nakamura
Cooling Systems Div., Design Dept.
Works on the development and design of cooling fans.

Hiromitsu Kuribayashi
Cooling Systems Div., Design Dept.
Works on the development and design of cooling fans.

19

SANYO DENKI Technical Report No.50 November 2020

Feature: Technologies for Helping Make New Dreams Come True

Power Technologies for Helping Make
New Dreams Come True
Chiaki Seki

1. Introduction

2. UPS Technologies

In recent years, damage to social infrastructure has

Conventionally, our UPSs have mainly been installed

become a major topic of news as many areas in Japan

indoors and used to back up servers, ICT equipment, andhave suffered large-scale power outages caused by natural

office equipment. They have also been incorporated into

disasters. Due to these circumstances, uninterruptible

industrial equipment. However, due to the proliferation of

power supplies (UPSs), which have conventionally been

mobile devices today and the lessons learned from natural

installed indoors for power backup of ICT equipment anddisasters including the Great East Japan Earthquake, it isplant facilities, will be expected to play a new role in society

anticipated that there will be increasing demand for powerby providing long-term and stable power backup of outdoor

backup solutions for distributed outdoor facilities such

equipment in the future.

as paid parking lots, traffic lights, base stations, outdoor

In addition, renewable energy sources are also attracting
more attention around the world as potential candidates

surveillance cameras, and emergency equipment, as shownin Figure 1.

to help realize a low-carbon society. For photovoltaic
generation systems that have been promoted by thefeed-in tariff scheme, there is a growing need for power
conditioners (i.e., renewable energy inverters) with isolated
output capability that can make use of generated power
during power outages caused by natural disasters. In
addition to photovoltaic power generation, wind and hydropower generation are also attracting more attention as
viable renewable energy sources. Wind and hydro power
generation systems require the use of rectifiers to convert
the AC power generated by the generation system into DC
power for use with power conditioners. We expect that the
combination of our power conditioners and a dedicatedrectifier can be used in not only wind and hydro power

Paid parking
lots

Traffic lights

Base stations

OutdoorsurveillancecamerasFig. 1 Examples of equipment used outdoors

generation, but also in fields new to us such as biomass andgeothermal power generation.

T he SA NUPS N11B -Li series, shown in Figure 2 ,Since all of these devices are installed outdoors, theyhas been designed for outdoor use. It features a wide

need to be able to withstand environmental changes andtemperature range (-20˚C to +50˚C) for safe use in extremely

have a high level of water and dust protection. They also

cold and hot regions.

need to provide maintenance-free operation for long

Furthermore, since outdoor installation is usually not

periods of time. In the following sections, we will introduce

conducive to regular maintenance and battery replacement,

technologies that are necessary for our products to be used

we designed this product to feature water and dust

in outdoor applications in new markets to meet these needs.

protection (protection rating of IP65(1)) and lithium-ion
batteries that provide long backup time in a small size.

SANYO DENKI Technical Report No.50 November 2020

20

These features enable it to achieve maintenance-free

The analysis helped us create a sealed structure that

operation. Through the development of this UPS, we have

prevents heat from building up in particular spots and does

acquired the technical expertise for installing power supply

not hinder UPS performance and reliability. As a result, we

products outdoors.

were able to successfully develop a highly reliable outdoor
UPS that has an IP65-rated sealed structure.
When installing equipment outdoors, consideration also
needs to be given to ensure that the effects of direct sunlight
does not impact the equipment. To achieve this, we attachedheat shields to the outside of the housing as shown in Figure
4, and optimized the spacing and ventilation structure of the
housing and heat shield by conducting exposure tests under
hot midsummer sun.
As a result, the surface temperature of the heat shield roseabout 15 to 20˚C above the ambient temperature due to the

1 kVA

1.5 kVA

Fig. 2 SANUPS N11B-Li series

direct sunlight, but the effect of the temperature rise on theinside of the housing was limited to about 5˚C.

(1) IP65 is a protection class defined in “JIS C 0920: Degrees ofProtection Provided by Enclosures (IP Code).” It stipulates
complete protection from dust and against water spray from all
directions.

To install electronic equipment outdoors and operate it
safely over a long period of time, it is necessary to improvethe equipment’s temperature resistance and housing
performance.
In the development of this UPS, we used some of thedesign techniques that we acquired through our previous
power conditioner developments and designed it to have asealed structure with an IP65 protection rating to enable

Heat shield(Attached to five sides)

it to be installed outdoors. To that end, we used thermal
fluid analysis to simulate internal heat flow and optimized
the structure and layout design to effectively circulate anddischarge heat to the outside by using the entire housing.
Figure 3 shows one example of thermal fluid analysis.

Fig. 4 Heat shield of the SANUPS N11B-Li series

3. Renewable Energy Inverter
Technologies
In addition to our conventional SANUPS P73H and
SANUPS P73J power conditioners (i.e., renewable energy
inverters) for photovoltaic generation systems, we developed
the SANUPS W73A for wind power and hydro power
generation systems. This product comes in two types: a grid-Fig. 3 Thermal fluid analysis modelof the SANUPS N11B-Li series

21

SANYO DENKI Technical Report No.50 November 2020

connected type and a grid-connected isolated type thatfeatures isolated operation capability.

Power Technologies for Helping Make New Dreams Come True

The grid-connected type power conditioner is unable

performed while taking the temperature rise of the diodes

to supply power in the event of a power grid failure, but

used in the rectification circuit into account. By making thethe grid-connected isolated type can continue supplying

cooling fins a part of the housing, this product satisfied thepower during times of emergency thanks to its isolated

required cooling performance even with a sealed structure

operation capability. This grid-connected isolated type isand also achieved quiet operation.
We expect that the combined use of our SANUPS W73A

also expected to be used as an independent power supply inpower conditioner and SANUPS W75A rectifier unit will be

non-electrified areas such as remote islands.
Wind and hydro power generation systems require thefurther introduced in renewable energy power generation

use of high-efficiency rectifiers to convert the AC powersystems, including wind and hydro power generation

generated by the generation system into DC power for use

systems, that use AC generators.
From the development of our previous power conditioners

with power conditioners.
Therefore, we newly developed the SANUPS W75A as aand this rectifier unit, we have now acquired the technicalrectifier dedicated for use with 10 kW or lower output windexpertise for converting the power generated by almostand hydro power generation systems.

all types of renewable energy generation systems into AC

Since the SANUPS W75A was designed to be installed

power, as shown in Figure 5.

outdoors with a power conditioner, it needed to have theMoving forward, our products can convert not only

same water and dust protection (IP65) as the combined

photovoltaic, wind, and hydro power, but also various otherpower conditioner to build a robust environmentally durable

types of renewable energy sources, such as biomass andsystem.

geothermal power, into AC power. We also expect thatTo this end, the unit makes use of a fanless passive air
cooling system. We decided to use large cooling fins for thiscustomizing customers’ equipment tailored to their needs
will further help expand new markets.

product based on the results of heat dissipation simulations

SANUPS P73J
SANUPS P73H

DC

Grid power

Photovoltaic generation
Solar panels
AC

DC

AC

Wind power generators
Hydro power generators
Other renewable energy
generation systems

New product
SANUPS W75ASANUPS W73A

Emergency
equipment

Generalequipment

Fig. 5 Power generation system overview

SANYO DENKI Technical Report No.50 November 202022

Power Technologies for Helping Make New Dreams Come True

4. Conclusion
We plan to continue to offer UPSs and power conditioners
that can safely be used in harsh outdoors environments, so
as to meet the expectations of our customers with the aim tocontribute to the realization of a low-carbon society.
In addition, we will endeavor to develop new technologies
to introduce higher quality power supplies into new fields
that require operations in unusually severe environments.
References(1) Yuhei Shoyama and 11 others: Development of the SmallCapacity UPS SANUPS A11K-Li and SANUPS N11B-Li Series
SANYODENKI Technical Report, No.44, pp. 22-28 (2017.11)(2) Takeo Murai and 10 others: Development of the SANUPS N11B-Li(3 kVA) Uninterruptible Power Supply
SANYODENKI Technical Report, No.45, pp. 22-26 (2018.5)(3) Masahiko Nagai: Development of UPS Products Equipped with
Lithium-Ion Batteries Creating Change and Offering New ValueSANYODENKI Technical Report, No.46, pp. 17-20 (2018.11)(4) Naohiko Shiokawa: Technical Developments in 2019 at Power
Systems Division
SANYODENKI Technical Report, No.49, pp.17-19 (2020.5)

23

SANYO DENKI Technical Report No.50 November 2020

AuthorChiaki Seki
Power Systems Div., Design Dept.
Works on the development, design,and quality control of power supplies.

New Product Introduction

Development of the SANUPS W75A
Rectifier Unit for Wind Powerand Hydro Power Generation Systems
Ryo Yoshizawa

Yoshinori Kaneko

Jun Takahashi

1. Introduction

Hiroshi Yamadaalso facilitates long-term operation and stable supply. As aresult, micro hydro power generation is attracting attention

In recent years, renewable energy sources such as

for its use in agricultural water and waterworks applications.

photovoltaic, wind, hydro, and biomass have been attracting

We have newly developed the SANUPS W75A rectifier

worldwide attention as potential candidates to help achieve

unit that can be used in wind power and hydro power

decarbonization. At the end of 2015, the Paris Agreement

generation systems with output capacities of 10 kW or less.

was decided as a common goal for the world. Moreover, inThis article introduces the features of this new product.

2018, Japan established its 5th Strategic Energy Plan. The(1)plan aims to make renewable energy “an economically selfsupporting, decarbonized main source of electricity” by2050. Moving forward, it is expected that the introduction ofrenewable energy will be promoted further.

2. Development BackgroundFigure 1 illustrates a simplified power generation system.
Wind and hydro power generation systems require the use

In addition to widespread photovoltaic power generation,of a rectifier to convert the AC power generated by thewind and hydro power generation are two other renewablegeneration system into DC power for use with its power

energy sources that are attracting increasing attention in

conditioners (i.e., renewable energy inverters).

Japan. Compared to other renewable energy sources, theHowever, there had been no standard rectifiers on the

introduction of wind power generation is expected to expand

market for generation systems with an output capacity of

due to its relatively low cost and applicability under the feed-

10 kW or less. Therefore, we have developed the SANUPS

in tariff scheme. As for hydro power generation, it has a

W75A as a rectifier that can be used in such power generation

higher energy conversion efficiency than other sources, andsystems.

Rectifier unit

or other power conditioners

図版Wind/hydro power
generators

123
Grid
power

英語

Con

英語

Tim

Fig. 1 Power generation system overview

SANYO DENKI Technical Report No.50 November 202024

3. Outline and Specificationsof the SANUPS W75AThe SANUPS W75A has a rated output capacity of 11 kW.
Table 1 shows its specifications and Figure 2 its appearance.
The main circuit uses a full-wave rectification method. It
converts the AC power generated by the system’s generators
into DC power for use with the power conditioners. Its
conversion efficiency is 99%(1), the highest level in theindustry.

Table 1 Specifications of the SANUPS W75A
Model no.

Items
Main circuit type

Full-wave rectification

Cooling system

Passive air cooling

Rated Output

11 kW

AC input

DC output

Brake

Remarks

The generator output should be 11 kW
or less. If exceeding this, contact us.

No. of phases/wires

3-phase 3-wire

Rated voltage

300 VAC

Maximumallowable voltage

420 VACTake necessary measures at the generator side
to ensure that a voltage higher than the maximum
allowable input voltage will not be applied.

106 to 420 VAC

Rated output range is 176 to 420 VAC.

Input operating
voltage range
Input frequency range

0 to 400 Hz

Rated input current

30 AAC

Number of circuits

1 circuit

Current type

Direct current

Rated voltage

420 VDC

Maximum current

45 ADC

Rated current

26 ADC

Voltage range

0 to 600 VDC

Operating voltage

530 VDC

Current

Mean: 25 A max.

Efficiency

99%

Acoustic noise

25 dBA or less

Operatingenvironment

Operatingtemperature range
Relative humidity
Altitude25

W75A113-25 to +60˚C

At a power factor of 0.7

Release voltage: 400 VDC
Efficiency measurement methodin accordance with JIS C 8961: 2008
At 1 m height,
1 m from the front of the unit
When using in combination
with a SANUPS W73A power conditioner
in the same environment

90% or less(non-condensing)2000 m max.

Protection rating

IP65

Housing material

SUS430SANYO DENKI Technical Report No.50 November 2020

Thickness 1.2 mm

Development of the SANUPS W75A Rectifier Unit for Wind Power and Hydro Power Generation Systems

This function constantly monitors the DC output voltage.
When the output voltage exceeds the specified value, thebrake function is activated to send current to the resistor
for brake. This prevents the input voltage of the power
conditioner from rising too high. In addition, the producthas a potential difference between the brake activation andrelease voltages to ensure that the control function is not
activated too often.

4.2 Generator speed contact output
In wind power and hydro power generation systems, it isnecessary at times to collect generator speed data.
T he SA NUPS W 75A comes with a contact output
terminal that outputs the generator’s output voltage
frequency. Generator speed can be measured using the

Fig. 2 SANUPS W75A

output voltage frequency. Moreover, generator speed can bemonitored by connecting a signal transducer to the contact
output terminal.

T he S A N U P S W 75A wa s desig ned to be u sed i n

In addition, by using the SANUPS W73A series andcombination with our SA NUPS W 73A series power

the SANUPS PV Monitor remote monitoring device inconditioners for three-phase 10 kW wind power andcombination, remote monitoring and data collection ofhydro power generation systems. This rectifier unit can begenerator speed can be done via a network, helping build

combined with power conditioners other than the SANUPS

smart grid systems.

W73A series products if their ratings such as DC output
voltage range are within the specifications shown in Table 1.

4.3 Temperature rise alarm contact output(1) Efficiency measurement is according to JIS C 8961. Our
SANUPS W73A power conditioner was used as the load.

temperature of its full-wave rectification circuit. The

T he S A N U P S W 75A c ont i nuou s ly mon itor s t herectifier unit comes with a contact output terminal thatturns off the full-wave rectification circuit by opening

4. Features of the SANUPS W75A

the circuit when the temperature of the circuit exceeds its

4.1 DC voltage rise control function(Brake function)

be enhanced by using the contact output to incorporate

specified value. Furthermore, the safety of the system cancontrols such as safe shutdown of the generator and power

The SANUPS W75A is equipped with a DC voltage

conditioner.

rise control function (brake function) to prevent damage
to the power conditioner in the event that the generator

4.4 Quiet operation

generates power in excess of the power conditioner’s input

The SANUPS W75A uses a fanless passive air coolingvoltage range. This function can be enabled by connecting

system to improve its quietness. The rectifier uses large

an external shunt resistor. Figure 3 shows the circuit block

cooling fins that take into account the temperature rise ofdiagram of the SANUPS W75A.

the diodes used in the full-wave rectification circuit. By
making the cooling fins a part of the housing, this productsatisfied the required cooling performance even with a

Generator
input

Full-wave
rectification

DC output

Brake function

Resistor
for brake

sealed structure and also achieved quiet operation.
Figure 4 shows the rear surface of the SANUPS W75A.

図版の文字

123

英語版用

CondensFig. 3 Circuit block diagram of the SANUPS W75A

英語版用

Times Ten

SANYO DENKI Technical Report No.50 November 202026

Development of the SANUPS W75A Rectifier Unit for Wind Power and Hydro Power Generation Systems

Cooling fins(2) Classifications defined in “JIS C 0920: Degrees of Protection
Provided by Enclosures (IP Code)”
IP65: Complete protection from dust and against water sprayfrom all directions. (Based on the protection performance test
defined by Japan Ship Machinery Quality Control Association
Research Institute of Marine Engineering)
References(1) “The 5th Strategic Energy Plan,” Agency for Natural Resources
and Energy, Ministry of Economy, Trade and Industry
https://www.enecho.meti.go.jp/category/others/basic_plan/
pdf/180703.pdf (2019.9.17)

AuthorFig. 4 Rear structure of the SANUPS W75A
Ryo Yoshizawa

4.5 Waterproof and dustproof

Power Systems Div., Design Dept.
Works on the development and design of power supplies.

With a sealed structure and fanless passive air coolingsystem, the SANUPS W75A achieves an IP65(2) water andYoshinori Kaneko

dust protection rating. The structure completely protects thePower Systems Div., Design Dept.
Works on the mechanical design of power supplies.

unit from dust and water sprayed from all directions.
This means that the unit is protected from rainwater, dust,
small insects, and animals. This enables the construction of

Jun Takahashi

an environmentally durable system that can be safely used

Power Systems Div., Design Dept.
Works on the development and design of power supplies.

outdoors for long periods of time.

4.6 Use in other power generation systems
The SA NUPS W75A has a wide range of voltages.
Specifically, it covers an AC input voltage range of 106 to
420 VAC and DC output voltage range of 0 to 600 VDC.
Use of this rectifier is not limited to wind and hydro power
generation systems. It can be used in a variety of renewableenergy generation systems that use 3-phase generators,
including biomass and geothermal power generation systems.

5. Conclusion
This article introduced the SANUPS W75A rectifier unit
for wind and hydro power generation systems. In addition to
the rectifier’s basic functions for converting the AC power
generated by generators into DC power, it also comes withcontact output and environmental durability.
We believe that this product will contribute to thepromotion of renewable energy generation systems such as
those for wind and hydro power generation.
We will continue to develop products in related fields
in a timely manner so that we can meet the needs of ourcustomers. By doing this, we expect that our products
will contribute to the spread of renewable energy and therealization of a low-carbon society.

27

SANYO DENKI Technical Report No.50 November 2020

Hiroshi Yamada
Power Systems Div., Design Dept.
Works on the development and design of power supplies.

Feature: Technologies for Helping Make New Dreams Come True

Technologies for Helping Make
New Dreams Come True

̶Servo technologies that contribute to medical, welfare, and food fields̶
Hideaki Kodama

Hidetoshi Hayashi

1. Introduction
There has been a heightened interest in human healthof late in light of the impact of infectious diseases and therotary axes, and does not require a large shield.

2.1 Overview of equipment
Figure 1 shows the appearance of the radiation therapychanges they have wrought on our ways of life. Medical

equipment. The main features of this equipment are:and welfare equipment has therefore also been advancing(1) T here is no need for a large scale shielded room.Because

greatly to meet these new challenges. Automation of foodproduction lines which sustain our lives has also been
accelerating in consideration of food safety, leading togreater expectations for servo systems products.
We have applied servo systems technologies that we haveself-shielded design.
(2) Radiation beams can be directed at the target area fromall directions using multiple rotary axes.
(3) I nnovative safety function: real-time dose verification
system.

cultivated over many years in the industrial machinery(4) T his new equipment achieves submillimeter levelmarket to the advanced medical, welfare, and food fields

irradiation precision, and is equipped with a function

with the aim of developing servo technology which can help

for correcting the patient position by providing image

people and machines work together harmoniously.

guidance during therapy.

Staying healthy to continue contributing to society is the
dream and desire of both people and society.
This article introduces our products and technologies
which contribute to human health and food safety. It will
highlight four examples in the medical, welfare, and foodfields where our servo products and technologies help makenew dreams come true.

2. Contributing to a Long,
Healthy Life (medical):Radiation Therapy Equipment

Fig. 1 Radiation therapy equipment appearance

Technology for cancer radiation therapy is advancing
daily. Dedicated stereotactic radiotherapy (SRT) for

The θ-axis used to rotate the irradiating part of theintracranial therapy these days is capable of delivering

equipment consists of multiple axes, allowing the affectedsubmillimeter (0.1 mm units) level irradiation precision, andarea to be irradiated from a wider angle. Accurate

is equipped with a function for correcting the position of thepositioning of the irradiation area is realized by these rotary

patient by providing image guidance during therapy.

axes together with the treatment bed used to convey theThis chapter introduces actuator (linear servo motor)

patient. The treatment bed has three axes, and is capabledevelopment technology that has contributed to theof three-dimensional motion. This allows the patient to be

development of new radiation therapy equipment that istreated by accurately directing radiation at the affected area

capable of generating radiation beams from a number ofof the head.

directions, including non-coplanar beams, by combining

We developed linear servo motors used in the rotary axes

SANYO DENKI Technical Report No.50 November 202028

for the irradiating part of the equipment, and the driving
axes which move the treatment bed.

The technology enabling low cogging thrust developed
here is being used in the development of a new need for
dedicated intracranial radiation therapy equipment.

2.2 Product specifications(linear servo motors)
This section provides an outline of the linear motors used
for the θ-axis. Figure 2 shows where our linear motors areused in the unit.

3. Contributing to a Long,
Healthy Life (medical):Mammography Units(breast cancer screening units)
Mammography is a dedicated radiographic technique for
imaging the breast. It is one of the most effective methodsof diagnostic imaging indispensable for the early detection

θ -axisIrradiating partof equipment can berotated by the linear
motors arranged
in arcof breast cancer. This chapter introduces the actuator
technology used in mammography units. This technology
makes it possible to detect changes at an early stage thatwould not normally be noticed by patients during their
daily lives.

3.1 Overview of equipment
Fig. 2 Where our linear motors are used

Figure 4 shows the mammography unit appearance, andFigure 5 shows where our DC servo motors are used in
the unit.

The θ-axis is a key axis which determines the irradiation

Our DC servo motors are used to rotate and move theangle, and load inertia to rotate the entire shielded structure

compression plate vertically. Mammograms are carried

about this axis is large. Therefore, positioning operation isout by first placing the area to be examined between therequired to be accurate.

unit’s two plates. The compression plate gradually applies

To achieve this, we developed a linear motor with magnets

pressure to the area and holds at a level appropriate for thearranged in the circumferential direction, and linear motor

examination, and the area is then irradiated with radiationcoils arranged in an arc. Conventional rotary motors requireand ultrasonic waves.

conversion mechanisms such as belt mechanisms, andfactors such as backlash and drops in rigidity hinder control.
However, high-accuracy control can be achieved using directdrive with arc linear motors.

Compression
plate

Figure 3 shows the appearance of the arc linear motor
armature.
Using direct drive offers a greater movement radius, andallows the required number of coils to be arranged, thereby
generating sufficient torque for rotation.
Cogging thrust generally increases by arranging magnets
in an arc, but a low level of cogging similar to that whenarranging magnets linearly has been realized by devising asystem which cancels cogging thrust inside the coils.

Fig. 4 Mammography unit appearance

Fig. 3 Arc linear motor armature

29

SANYO DENKI Technical Report No.50 November 2020

Technologies for Helping Make New Dreams Come True ̶ Servo technologies that contribute to medical, welfare, and food fields ̶

For the vertical driveof the compression
plate

emitted from the motor. Furthermore, our SANMOTION K
DC servo motors have a revised structure that achieved
reduced noise (1) . This allows patients to be examined
without having to worry about stressful motor noise.

For thevertical driveof the wholemoving partFor the rotary driveof the whole moving
partFig. 5 Mammography unit motor arrangement

4. Contributing to Living
Independently (welfare):Wearable Robots
for Active Living Support(2)With its super-aging society, Japan is seeking ways
to allow the elderly to continue to enjoy healthy lives
without assistance. This chapter introduces “humanfriendly wearable robot” development technology involving

3.2 Human body-friendly control

actuators and servo amplifiers we have developed. ThisThe breasts of those undergoing examination differ

robot has been designed to assist those who have becomein many ways in terms of size, shape, and firmness, andphysically impaired due to diminished physical ability, or

thus delicate pressure control of the compression plate is

who have been injured in the course of their work.

required. The control can be easily done with DC servo
motors. By simply monitoring the current flowing to DC

4.1 Overview of equipment

servo motors, the subtle pressure applied to the plate can

The “human-friendly wearable robots,” in which we were

easily be controlled, minimizing physical strain such as pain

involved in the development, have been designed to bein the area being examined.

lightweight and easy and comfortable to wear. The purpose ofthis robot is to help the elderly or patients walk independently,

3.3 Safety ensured by low-voltage motors
Since mammography involves the compression plate

to assist with nursing care of them, and for the rehabilitation of
those with disabilities.

coming into direct contact with the human body, safety
against electrical shock had to be ensured for electric
actuators. To this end, it is necessary to use servo motors that

The two main features of this robot are:(1) C oordinated control (control technology)

support 40 VDC or lower voltages. Our SANMOTION K∙ User’s movement can be improved more naturally

series DC servo motors meet this requirement, and we have a

not by forcibly improving their movement throughstandard lineup of low-voltage models.(1)robot movements, but by its human-like cooperative
motion assistance. That is, despite being a robot, this

3.4 Reliability in high-radiation
environments

robot can assist the user’s movement just as a humanbeing does.

The structure of DC servo motors is such that control isrelatively easy when compared with AC servo motors, and(2) Non exoskeleton type exterior mechanisms

commutation sensors are not required unlike AC servo∙ T hese wea rable robot s have a pla st ic, non-motors. There is no need for electronic components such

exoskeleton structure that mimics the human skeletal

as hall sensors, ensuring highly reliable control even in

structure rather than the rigid metallic exoskeleton

environments exposed to high levels of radiation.

structure often seen in conventional assistancerobots, making it both lightweight and easy-to-wear,

3.5 Equipment noise reduction

ensuring maximum freedom of movement.

Mammography often involves placing electric actuators inlocations relatively close to the patient body. Consequently,

Figure 6 shows the configuration of a wearable robot This

noise produced by actuators and harmonic noise generated

wearable robot consists mainly of a jointed frame, which

by inverters can sometimes cause the patient discomfort

forms the external mechanism worn by the user, an actuatoror stress. The structure of DC servo motors is such that

unit (4 axes) that assists the user’s motion, and a controller thatthe harmonic noise-producing windings are located in thecontrols the actuator. We developed the linear servo motors inrotating part of the motor, reducing the harmonic noise

the actuator unit and the servo amplifier in the controller.

SANYO DENKI Technical Report No.50 November 202030

Controller

multiple LSI components such as CPUs, ASICs, andmemory. To reduce the number of components used in
the servo amplifier, we employed the CPU-based current
detection function and encoder interface function, createdsoftware to control the current that had previously been
done by a ASIC, and developed a control circuit capable

Jointed frameof controlling two motor axes with a single CPU. Also, bydeveloping a compact, lightweight 4-axis integrated servo
amplifier capable of being stored in the controller on theback, we have succeeded in realizing the product concept ofActuator

Fig. 6 Wearable robot equipment configuration“a robot that can be worn just like clothes.”

5. Contributing to Improving Food
Environments:
Development of Robots
for Food Packaging Lines
In line with changes in food culture and life style, new

4.2 Actuator configurationand motor specifications
The actuator consists of a gear, motor, encoder, and torquesensor. A palm-sized flat motor is used.

food supply methods are being established involving theuse of convenience stores and courier services. Greater
emphasis has been placed on safety and hygiene in foodprocessing and packaging plants, but the aging population inWith wearable robots, the wearer must bear an extra load

Japan has made it difficult to secure the labor required for

determined by the weight and size of the actual device, andsuch work. To meet this challenge, the use of production site

this demands stricter conditions than those required by otherautomation and unmanned operation is accelerating.

robots in terms of size and weight reduction. To achieve the

The use of high-speed parallel link robots for foodfirst aim of miniaturization, we developed a flat structure

production facilities with high production volumes has beenwith bearings and the encoder arranged on the inside of

attracting much attention.

the electromagnetic part of the motor. To keep weight to aThis chapter introduces parallel link robot development

minimum, we developed a mechanism which exerts minimal

technology that uses our motion controllers for use in

restrictions on the user with a lightweight design achievedhandling robots for food production lines.

through such means as making the frame thinner.

5.1 Overview of equipment
4.3 Development of servo amplifier
for wearable robots

The equipment we were involved in developing was a postpackaging box filling line process using a parallel link robot.

We have also been striving to reduce the size and weight

An image-processing unit detects products being carriedof the servo amplifier used to drive the motors to realize

on a belt conveyor. A robot then follows the products, picks

the concept of “can be worn just like clothes” for a robotic

them up, and finally packs them into boxes. This equipment

suit worn on the body to support the independence of thoseis collectively known as a conveyor tracking system. Figure 7

requiring care.

shows an overview of the system.
The box filling process requirements can be met with

4.3.1 Miniaturization and weight reduction

processes. However, our motion controller has been revisedon the body; heat dissipation and safety have been assured

to add capabilities to allow installed robots to be changed,

while employing an open frame configuration with a control

moved, and expanded freely.

board and power board so as not to compromise comfort.
For increased wearability, we designed the servo system tobe lightweight and compact so that it can fit in the controller
box on the back.
Our standard servo amplifiers control motors with31

a robot and belt conveyor coordinated with upstream

The entire servo system, including the drive unit, is worn

SANYO DENKI Technical Report No.50 November 2020

Technologies for Helping Make New Dreams Come True ̶ Servo technologies that contribute to medical, welfare, and food fields ̶

Ethernet

Image
processing
device(option)SANMOTION C

motion controller

Parallel linkrobot
Teaching
pendant

Camera(option)(option)EtherCATSANMOTION R

EtherCAT servo amplifier
Programmabletouch panel(option)Belt conveyor

Encoder signal

Fig. 7 Conveyor tracking system configuration

5.2 Robot control technology
There are a number of issues involved in developing
a production system that uses robots, such as training
p er s on nel to h ave rob ot ex p er t i s e a nd prolonge ddevelopment periods.
To solve such issues, our SA NMOTION C motion
controller features technologies and functions to support
robot development, which are introduced below.

5.2.1 Parallel link robot posture control
As shown in Figure 8, the SANMOTION C motion
controller has a mechanism setting tool, which makes it
possible to control robot posture easily.
Robot posture can be controlled simply by setting the typeof robot to be developed, arm length, and gear ratio. Posturecontrol does not require complicated calculations, therefore
the burden of program development placed on customers is
reduced.

Fig. 8 Robot mechanism setting tool

SANYO DENKI Technical Report No.50 November 202032

Food production lines are expected to use multiple robots,
therefore flexibility is required in terms of expanding robot
processes and making installation changes. Figure 9 shows
the construction and installation method of the special
parallel link robot with which our motion controller was
combined to save space in the production line.

Fig. 11 Belt conveyor and camera setting screen

Table 1 Example of main robot language
commands
Command nameFig. 9 Parallel link robot specialized mechanisms
and construction methods

Description

PTP

Point-to-point motion

LIN

Linear interpolation motion

CIRC

Circular interpolation motion

PTPRelWe p r o v i d e a d e d i c a t e d t e a c h i n g p e n d a n t f o r

WaitFinished

SANMOTION C shown in Figure 10 to allow robot motion

RefRobotAxis

Distance-specified PTP motion
Distance-specified linear
interpolation motion
Robot stop
Wait for robot command
to process
Homing operation

to be programmed easily. The wizard navigation, shown

TOOL

Tool coordinates settingin Figure 11, makes it easy to make complex belt conveyor

Ovl

WaitTime

Overlap setting (Path)
Acceleration/deceleration
curve setting
Wait time (timer)

DIN.Wait

Wait for digital input

Dout. Set

Digital output setting (BOOL)

WHILE ... DO

Iterative control

IF ... THEN

Branch instruction

LINRel

5.2.2 Teaching/programming function

and camera installation adjustments. Robot operationcommands shown in Table 1 can be used to operate
robots easily. These functions allow robot motion to be
programmed quickly.

StopRobot

Ramp

Using the robot development support technology ofSANMOTION C, even users with no robot expertise candevelop robot motion programs quickly. By providing
total support with robot installation, development, andprogramming, we contribute to the realization of unmanned
operation and automation.
Front view

Side viewFig. 10 Teaching pendant appearance

33

SANYO DENKI Technical Report No.50 November 2020

Technologies for Helping Make New Dreams Come True ̶ Servo technologies that contribute to medical, welfare, and food fields ̶

6. Conclusion
This article introduced the following four cases where our
products and technology are used to help make new dreams
for people’s lives come true.

Author

Hideaki Kodama
Servo Systems Div., Design Dept. 2
Works on the design and development of controllers.

(1) Linear servo motor technology for radiation therapy
equipment(2) DC servo motor technology used in mammography(3) Servo technology for wearable robots

Hidetoshi Hayashi
Servo Systems Div., Design Dept. 1
Works on the design and development of servo motors.

(4) Motion control technology for food packaging parallel
robots
These servo technologies support medical treatment andfood environments. Servo technologies tend to be thoughtof as technologies used in industrial machinery only, but
as this article has highlighted, servo technology also has asignificant role to play in medical and welfare equipment,
as well as equipment for the food production industry. We
will continue to develop servo technology that allows people
and medical and welfare equipment to work together, andprovide products and services that can contribute to good
health and making people happy.
References(1) Daigo Kuraishi and 11 others: SANMOTION K Series DC Servo
Motors,SANYO DENKI Technical Report, No.48 pp. 36-40 (2019.11)(2) Tsukahara et al.: Effects of gait support in patientswith spinocerebellar degeneration by a wearable robot basedon synchronization control,
Journal of NeuroEngineering and Rehabilitation (2018.9)(3) Hiroshi Okino and 3 others: Development of Motion Controller
SANMOTION C,
SANYO DENKI Technical Report, No.21 pp. 34-38 (2006.5)

SANYO DENKI Technical Report No.50 November 202034

New Product Introduction

Development of SANMOTION C
Wireless Adapter 3A
Shigeki Sato

Tomonobu Tazaki

Hiroto Endo

Naoto Miura

Masayuki Mizutani

Ryunosuke Murakami

1. Introduction
In the manufacturing industry, production equipmentthat uses wireless communication technology has beendeveloped to improve production efficiency and facilitate
timely responses to customer needs and market changes.

Fig. 1 Wireless Adapter 3A

As one example, notifications of production equipment
abnormalities can be sent remotely through wirelesscommunication so that problems can be quickly resolved.
As such, production equipment is required to support such

（56.5）

functionality to effectively use wireless communication
demand for add-on products that can easily add wireless

20

communication features to make existing production
equipment IoT-ready.

（21.8）

43

for improved maintainability. In addition, there is also

To meet th is dema nd, we developed the Wirele ss
SANMOTION C S100 motion controller (hereinafter, S100)
with wireless capabilities. The “3A” in the product name

11.5

Adapter 3A as an add-on product that can provide thestands for: Anytime (can check information whenever it isneeded), Anywhere (can be used no matter in which country
it is installed), and Anything (can connect to a PC or smart

Fig. 2 Dimensional drawingof Wireless Adapter 3A (Unit: mm)

device).
This article will introduce the features of this new product.

2. Product Overview

Cable wiring space
70 [mm]

2.1 Appearance and dimensions
Figure 1 shows the appearance of the Wireless Adapter 3A
and Figure 2 shows its dimensional drawing.
The new product comes with a USB interface and can beused by connecting it to the USB connector on the front of
the S100. When mounted to the S100, it fits within the cablewiring space so as not to interfere with other equipment (seeFigure 3). In addition, the adapter has an easy-to-grasp grip
on its side to prevent it from slipping. This design makes it
easy to be connected to and disconnected from the S100 (seeFigure 4).

35

SANYO DENKI Technical Report No.50 November 2020

Fig. 3 Illustration of spacing when mounted
to the S100

Development of SANMOTION C Wireless Adapter 3AThe new product has two operation modes: an accesspoint mode (acting as a master network station) and a station
mode (acting as a slave network station). In the access point
mode, wireless devices can be easily connected to each othereven in environments without wireless networks. Whena wireless network is available, in the station mode, theproduct can be used as a slave network station.

Fig. 4 Side grip
Table 1 shows the basic specifications of the Wireless
Adapter 3A.

Table 1 Basic specifications
Interface
Wireless standard
Frequency band

USB 2.0 Type A
Compliantwith IEEE 802.11 b/g/n
2.4 GHz

Data rate

IEEE 802.11b: Up to 11 Mbps
IEEE 802.11g: Up to 54 Mbps
IEEE 802.11n: Up to 72.2 Mbps

Maximum numberof connectable units

3

Operation mode
Security
Operatingtemperature
Storage temperature
Humidity

Access point mode
Station mode
WPA2-PSK (AES)
0 to +55°C-40 to +70°C
10 to 95% (non-condensing)

Dimensions (W×H×D) 21.8 × 11.5 × 56.5 mm
Mass

Approx. 10 g

Wireless standard

TELEC (Japan)
FCC (USA)
ISED (Canada)
CE (Europe)
SRRC (China)
NCC (Taiwan)
NBTC (Thailand)

Fig. 5 Wireless LAN setting screen

3.2 Complies with IEEE 802.11b/g/n(2.4 GHz) wireless standards
Table 2 shows major wireless standards. The new productuses the IEEE 802.11b/g/n wireless standards that provide
fast and long-distance communication, and supports the
2.4 GHz frequency band that provides greater penetration
through obstructions such as walls.
T he 2 .4 GH z band is susceptible to inter- channelinterference because it is used by a large number of devices.
However, the new product comes with a function forchecking ambient signal conditions. It automatically selects
the best channel based on signal conditions, providing stablecommunications.

3.3 Compliant with radio lawsof many countries
When exporting production equipment that comesequipped with wireless devices, it is necessary to meet the

3. Features

requirements of the radio communication regulations of

3.1 Helps build wireless networks easily

the production equipment would need to be replaced with

importing countries. This means that the wireless devices ofWireless features can be used by simply connecting thedevices compatible with the regulations of the importing

new product to the USB interface of the S100. Wirelesscountry. However, the new product doesn't have to be

settings can be configured using the SA NMOTION

replaced. By simply reconfiguring the setting parameters,

C Software Tool, an integrated development tool (seeit can be made compliant with the laws of many countries,

Figure 5). It does not require any advanced knowledge ofincluding Japan, the United States, Canada, countries in

networks and its setting parameters have been kept to a

Europe, China, Taiwan, and Thailand.

minimum.

SANYO DENKI Technical Report No.50 November 202036

Table 2 Wireless standards
Items

Frequency[MHz]

Communication
speed[Mbps]

Communication
range
[m]

Numberof connectable
units
[Qty]

Radio wave
interferencePowerconsumption

Versatility

Wireless LAN
IEEE 802.11n

2400

65 to 300

100

32

Poor

Poor

Good

Bluetooth2400

1 to 24

20

7

Average

Average

Average

ZigBee2400
920

0.02 to 0.25

50

65,536

Good

Good

Poor

3.4 Shortens production facility downtime
By combining the new product with the web-based data

Factory network

visualization function of the S100, operators can view the

Wireless connections

status of production equipment in real time using smart
devices (see Figure 6). In the event of an abnormality,
operators are instantly notified of the circumstances so thatthey can quickly investigate the cause and perform recovery
work. This minimizes equipment downtime.

Wirings of production equipment is unnecessary,so the manufacturing line layout can be changed easily

Web browser
S100

Fig. 7 Easy layout change

Smartphone
Tablet3.5 Improved maintainability
Figure 8 compares wired and wireless environments.
Production equipment may sometimes be installed inFig. 6 Visualizationof production equipment conditions

locations where maintenance is difficult or even dangerous.
The new product is especially useful in these environments.
It enables operators to remotely diagnose failures in
production equipment, perform program maintenance,

In addition, it is often the case in manufacturing sitesthat communication of information between devices isconfigure servo systems, and update firmware from a safe
location, greatly improving maintainability.

performed using wired connections. Therefore, changing
the layout of a manufacturing line will require time-Work with wired connections

Work with wireless connections

consuming wiring work. In the event that a cable is damaged
during wiring, this could result in a significant amount of
manufacturing downtime. By using the new product to makecommunication wireless, wiring work becomes unnecessary
and the layout of manufacturing lines can be flexibly
changed with no risk of damaging cables (see Figure 7).

37

SANYO DENKI Technical Report No.50 November 2020

PC

Smart
deviceOperated fromremote locations

Fig. 8 Comparison of maintenanceDevelopment of SANMOTION C Wireless Adapter 3A

4. Conclusion
This article introduced the features of the Wireless
Adapter 3A. To recap, it can do the following:(1) It can connect to the USB interface of the S10 0
to provide the S100 with wireless capabilities that

AuthorShigeki Sato
Servo Systems Div., Design Dept. 2
Works on the design and developmentof Servo Systems products.

simplify the construction of a wireless environment.
(2) It complies with the radio communication regulationsof various countries, and doesn't have to be replacedwhen imported.
(3) It prov ide s w i rele s s c apabi l it ie s t hat shor ten

Tomonobu Tazaki
Servo Systems Div., Design Dept. 2
Works on the design and developmentof Servo Systems products.

product ion equ ipment dow nt i me a nd i mprove
maintainability.
The new product makes it easy to add wireless capabilities
to the SANMOTION C S100 motion controller. We expect

Hiroto Endo
Servo Systems Div., Design Dept. 2
Works on the design and developmentof Servo Systems products.

that it will improve maintainability and contribute to theeasy construction of manufacturing lines. We will continue

Naoto Miurato develop products that meet market needs and help create

Servo Systems Div., Design Dept. 2
Works on the design and developmentof Servo Systems products.

new value for our customers' manufacturing.

Masayuki Mizutani
Servo Systems Div., Design Dept. 2
Works on the design and developmentof Servo Systems products.

Ryunosuke Murakami
Servo Systems Div., Design Dept. 2
Works on the design and developmentof Servo Systems products.

SANYO DENKI Technical Report No.50 November 2020

38

Memo

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SANYO DENKI Technical Report No.50 November 2020

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November
2020

https://www.sanyodenki.com

Published in Japan on November 15, 2020 by SANYO DENKI CO., LTD.
Published semi-yearly
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